US20130150271A1 - Metalworking fluid composition and method for its use in the machining of compacted graphite iron - Google Patents

Metalworking fluid composition and method for its use in the machining of compacted graphite iron Download PDF

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US20130150271A1
US20130150271A1 US13/709,521 US201213709521A US2013150271A1 US 20130150271 A1 US20130150271 A1 US 20130150271A1 US 201213709521 A US201213709521 A US 201213709521A US 2013150271 A1 US2013150271 A1 US 2013150271A1
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composition
fluid composition
iron
machining
fluid
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Robert D. Evans
Kuan Zhong
Steven R. Thomas
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Quaker Chemical Corp
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Quaker Chemical Corp
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Assigned to QUAKER CHEMICAL CORPORATION reassignment QUAKER CHEMICAL CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EVANS, ROBERT D., THOMAS, STEVEN R., ZHONG, Kuan
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    • C10N2030/06—Oiliness; Film-strength; Anti-wear; Resistance to extreme pressure
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2040/00—Specified use or application for which the lubricating composition is intended
    • C10N2040/20—Metal working
    • C10N2040/244—Metal working of specific metals
    • C10N2040/246—Iron or steel

Definitions

  • Cast irons may be used in the production of many industrial components. Certain types of cast irons such as compacted graphite iron may be difficult to machine; the metal cutting and grinding often necessary in the fabrication of industrial components may present challenges and difficulties resulting in, for example, rapid and accelerated rates of tool wear, as well as in reduced quality of the part produced.
  • Gray cast iron has traditionally been used for the production of engine blocks, cylinder heads, as well as various other automotive components.
  • the graphite in gray cast iron has a flake-like structure.
  • the predominance of interconnecting graphite flakes gives rise to a high level of discontinuities and stress concentration effects in the matrix and subsequently gives rise to the properties characteristic of gray irons such as good thermal conductivity, damping capacity, and good machinability properties.
  • gray cast iron is easily machined at low production costs, (higher metal removal rates with long tool life).
  • compacted graphite iron has a graphite structure much like that of coral. Such a graphite structure produces lower levels of discontinuities and stress concentration effects within the metal, giving rise to higher strength and toughness properties, as well as lower machinability.
  • gray cast iron In addition to graphite structure differences, there are significant compositional differences between gray cast iron and compacted graphite iron which also are largely responsible for the differences in the machinability of these two metals.
  • the presence of sulfur in gray cast iron is considered to be a critical factor associated with the high machinability of this metal.
  • an iron-machining composition includes water; a lubricant ester; and a sulfur-containing lubricant additive.
  • a lubricant ester or combination of lubricant esters is present in an amount of about 1 wt % to about 50 wt %, and may include a polyol ester; a glycerol-based ester; and/or an ester selected from those of C 12 toC 18 fatty acid esters of 2,2 dimethyl-1,3-propanediol, 2-propanol, 1,1,1, tris(hydroxymethyl)propane, 2-hydroxy-1,3-propanediol, 2,2-bis(hydroxymethyl)-1,3-propanediol, and 1,2,3-propanetriol.
  • Suitable esters also may include those produced by the initial reaction of the polyol with ethylene oxide and/or propylene oxide followed by subsequent esterification, to yield a polyoxyalkylated polyol ester.
  • Suitable esters also include those produced by the condensation of hydroxyl-functionalized fatty acids, such as ricinoleic acid, to yield oligomeric and polymeric esters.
  • an iron-machining composition includes fatty acids such as those containing saturated and unsaturated chains of between 12 and 22 carbons, in an amount of about 0 wt % to about 12 wt %.
  • an iron-machining composition includes about 0 wt % to about 30 wt % of a boric acid-amine adduct whereby the boric acid amine adduct may be comprised of a mixture of one or more structures including the amine salts of boric acid, boric acid-alkonaolamine esters including cyclic boroxine esters, and polyborate amine salts.
  • an iron-machining composition includes about 0 wt % to about 50 wt % of a mineral oil.
  • Suitable mineral oils may be pure or a mixture of mineral oils such as naphthenic and paraffinic oils of between about 15 cSt and about 30 cSt at 40 degrees centigrade.
  • an iron-machining composition includes about 4 wt % to about 10 wt % of a mixture of nonionic and anionic emulsifiers.
  • a method of machining iron includes applying a fluid composition of the present invention (referred to as fluid concentrate) as a water dilution whereby prior to use in machining, the composition of the present invention is first diluted with water to give between 1% to 100% concentration of the fluid concentrate.
  • a fluid composition of the present invention referred to as fluid concentrate
  • such application may reduce tool wear during machining of iron such as by about 5% to about 90% as compared to conventional lubricant fluids.
  • the machined iron is compacted graphite iron.
  • FIG. 1 shows axial forces measured during drilling
  • FIG. 2 shows torque measured during drilling
  • FIG. 3 illustrates tool wear after drilling
  • FIG. 4 shows tool wear with various machining fluids
  • FIG. 5 shows cutting forces with various machining fluids
  • FIG. 6 shows tool wear obtained on drills
  • FIG. 7 shows the surface finish measured over one hundred thirty holes reamed.
  • compositions and methods of some embodiments of the present invention relate to metalworking fluid compositions and methods for their use in the machining of metal, such as iron.
  • compositions and methods of the present invention relate to machining compacted graphite iron (also referred to as “CGI” or “vermicular iron”).
  • CGI compacted graphite iron
  • fluid compositions and methods of application of the present invention which, when used in the metal cutting and grinding processes performed on iron such as compacted graphite iron, may significantly extend the lifetime of the tools used by effectively reducing wear, and may improve the quality of the part produced.
  • fluid compositions of the present invention include at least an ester lubricant in combination with a sulfur-containing lubricant additive.
  • fluid compositions of the present invention include one or more ester lubricants.
  • Suitable ester lubricants may include polyol and natural carboxylic esters such as long chain (C 12 -C 22 ) carboxylic esters of branched chained or cyclic mono, di and polybasic alcohols.
  • Suitable ester lubricants may also include alkoxylated polyol esters such as long chain (C 12 -C 22 ) carboxylic esters of branched chained or cyclic mono, di and polybasic alcohols whereby the polybasic alcohol is alkoxylated prior to formation of the carboxylic ester.
  • Suitable esters may also include those produced by the condensation of hydroxyl-functionalized fatty acids, such as ricinoleic acid, to yield oligomeric and polymeric esters.
  • suitable ester lubricants include esters containing a carboxylic acid moiety selected from carboxylic acids with saturated and unsaturated alkyl chains of between 12 to 22 carbons in length, whereby fatty acid(s) are reacted with a mono or polyfunctional alcohol selected from but not limited to 2,2 dimethyl-1,3-propanediol, 2-propanol, 1,1,1, tris(hydroxymethyl)propane, 2-hydroxy-1,3-propanediol, 2,2-bis(hydroxymethyl)-1,3-propanediol, and 1,2,3-propanetriol, to form the ester useful within the current invention.
  • a fluid composition contains an ester lubricant in an amount of about 1 wt % to about 50 wt % of the fluid composition; about 2 wt % to about 40 wt % of the fluid composition; about 3 wt % to about 35 wt % of the fluid composition; about 4 wt % to about 30 wt % of the fluid composition; about 5 wt % to about 25 wt % of the fluid composition; about 6 wt % to about 20 wt % of the fluid composition; about 6 wt % to about 15 wt % of the fluid composition; about 7 wt % to about 10 wt % of the fluid composition; about 1 wt % of the fluid composition; about 2 wt % of the fluid composition; about 4 wt % of the fluid composition; about 6 wt % of the fluid composition; about 8 wt % of the fluid composition; about 10 wt % of the fluid composition; about 12
  • a fluid composition of the present invention includes one or more sulfur-containing lubricant additives.
  • Suitable sulfur-containing additives may include sulfurized alpha olefins, di-branched alkyl tri and polysulfides, sulfur containing carboxylic acids, complex sulfurized esters, and/or dialkyl polysufides.
  • suitable sulfur-containing compound include structures as shown in Formula 1:
  • a fluid composition include a sulfur-containing lubricant additive in an amount of about 0.1 wt % to about 20 wt % of the fluid composition; about 0.2 wt % to about 18 wt % of the fluid composition; about 0.3 wt % to about 16 wt % of the fluid composition; about 0.4 wt % to about 14 wt % of the fluid composition; about 0.5 wt % to about 12 wt % of the fluid composition; about 0.6 wt % to about 10 wt % of the fluid composition; about 0.7 wt % to about 10 wt % of the fluid composition; about 0.8 wt % to about 9 wt % of the fluid composition; about 0.9 wt % to about 8 wt % of the fluid composition; about 1 wt % to about 7 wt % of the fluid composition; about 7 wt % of the fluid composition; about 0.1 wt % of the fluid composition; about
  • composition of this invention may also contain other compounds commonly used in many metal cutting lubricant fluids. Such compounds and concentration of such compounds are described below.
  • a fluid composition of the present invention includes fatty acids.
  • Suitable fatty acids may include but are not limited to those of between 12 and 22 carbons in chain length incorporated into the formula as a single fatty acid type or as a combination of two or more fatty acids.
  • a fluid composition of the present invention includes fatty acids in an amount of about 0 wt % to about 30 wt % of the fluid composition; about 0.1 wt % to about 30 wt % of the fluid composition; about 0.5 wt % to about 25 wt % of the fluid composition; about 1 wt % to about 20 wt % of the fluid composition; about 2 wt % to about 17 wt % of the fluid composition; about 3 wt % to about 15 wt % of the fluid composition; about 0.1 wt % of the fluid composition; about 0.5 wt % of the fluid composition; about 1 wt % of the fluid composition; about 2 wt % of the fluid composition; about 3 wt % of the fluid composition; about 4 wt % of the fluid composition; about 5 wt % of the fluid composition; about 6 wt % of the fluid composition; about 7 wt % of the fluid composition; about
  • a fluid composition of the present invention includes an amine or mixture of amine compounds.
  • Such amines include ethanolamine, triethanolamine, 2-amino-2-methyl propanol, dicyclohexylamine, and diglycolamine.
  • a fluid composition of the present invention includes an amine or mixture of amines in an amount of about 0 wt % to about 30 wt % of the fluid composition; about 0.1 wt % to about 30 wt % of the fluid composition; about 0.5 wt % to about 25 wt % of the fluid composition; about 1 wt % to about 20 wt % of the fluid composition; about 2 wt % to about 17 wt % of the fluid composition; about 3 wt % to about 15 wt % of the fluid composition; about 0.1 wt % of the fluid composition; about 0.5 wt % of the fluid composition; about 1 wt % of the fluid composition; about 2 wt % of the fluid composition; about 3 wt % of the fluid composition; about 4 wt % of the fluid composition; about 5 wt % of the fluid composition; about 6 wt % of the fluid composition; about 7 wt %
  • a fluid composition of the present invention includes a boric acid-amine adduct whereby the boric acid amine adduct may be comprised of a mixture of one or more structures which include the amine salts of boric acid, boric acid-alkonaolamine esters including cyclic boroxine esters, as well as polyborate amine salts.
  • Suitable adducts can be prepared by the reaction of boric acid with a single or mixtures of amines selected from but not limited to monoethanolamine, triethanolamine, 2-amino-2-methyl propanol, dicyclohexylamine, and diglycolamine, reacted at either stoichiometric quantities or with slight excess of the amine component.
  • a fluid composition of the present invention includes an amine boric acid adduct in an amount of about 0.1 wt % to about 30 wt % of the fluid composition; about 1 wt % to about 25 wt % of the fluid composition; about 2 wt % to about 20 wt % of the fluid composition; about 3 wt % to about 17 wt % of the fluid composition; about 5 wt % to about 15 wt % of the fluid composition; about 0.1 wt % of the fluid composition; about 0.5 wt % of the fluid composition; about 1 wt % of the fluid composition; about 2 wt % of the fluid composition; about 3 wt % of the fluid composition; about 4 wt % of the fluid composition; about 5 wt % of the fluid composition; about 6 wt % of the fluid composition; about 7 wt % of the fluid composition; about 8 wt % of the fluid composition; about 9 w
  • a fluid composition of the present invention includes an amine salt of a short chain dicarboxylic acid.
  • Suitable amine salts of short chain dicarboxylic acids include but are not limited to those whereby the amine diacid acid salt is comprised of a single or mixture of amines selected from monoethanolamine, triethanolamine, 2-amino-2-methyl propanol, dicyclohexylamine, and diglycolamine, reacted with a short chain dicarboxylic acid selected from those containing between 4-12 carbon atoms.
  • a fluid composition includes one or more amine salts of a short chain dicarboxylic acid in an amount of about 0.1 wt % to about 20 wt % of the fluid composition; about 0.5 wt % to about 15 wt % of the fluid composition; about 1 wt % to about 10 wt % of the fluid composition; about 1.5 wt % to about 9 wt % of the fluid composition; about 2 wt % to about 8 wt % of the fluid composition; about 0.1 wt % of the fluid composition; about 0.5 wt % of the fluid composition; about 1 wt % of the fluid composition; about 1.5 wt % of the fluid composition; about 2 wt % of the fluid composition; about 3 wt % of the fluid composition; about 4 wt % of the fluid composition; about 5 wt % of the fluid composition; about 6 wt % of the fluid composition; about 7 wt %
  • a fluid composition of the present invention includes a mineral oil.
  • Suitable mineral oils may be pure or a mixture of mineral oils such as naphthenic and paraffinic oils.
  • a suitable mineral oil or mineral oil blend may have a final viscosity of about 5 cSt to about 35 cSt at 40 degrees centigrade; about 10 cSt to about 30 cSt at 40 degrees centrigrade; about 15 cSt to about 25 cSt at 40 degrees centrigrade; about 5 cSt at 40 degree centigrade; about 10 cSt at 40 degree centigrade; about 15 cSt at 40 degree centigrade; about 20 cSt at 40 degree centigrade; about 25 cSt at 40 degree centigrade; about 30 cSt at 40 degree centigrade; or about 35 cSt at 40 degree centigrade.
  • a fluid composition of the present invention includes a mineral oil or mineral oil blend in an amount of about 0 wt % to about 75 wt % of the fluid composition; about 0.1 wt % to about 75 wt % of the fluid composition; about 0.1 wt % to about 70 wt % of the fluid composition; about 0.1 wt % to about 65 wt % of the fluid composition; about 0.1 wt % to about 60 wt % of the fluid composition; about 0.1 wt % to about 55 wt % of the fluid composition; about 1 wt % to about 50 wt % of the fluid composition; about 2 wt % to about 45 wt % of the fluid composition; about 5 wt % to about 40 wt % of the fluid composition; about 10 wt % to about 35 wt % of the fluid composition; about 15 wt % to about 30 wt % of the fluid composition; about 20
  • a fluid composition of the present invention includes one or more emulsifiers.
  • Suitable emulsifiers may include but are not limited to a mixture of nonionic and anionic emulsifiers selected from those commonly known in the art and typically used in water based metalworking fluids.
  • suitable emulsifiers include alkaline metal salts of alkylaryl, alkyl and aryl sulfonic acids; alkoxylated long chain alcohols of between C 12 -C 22 in length; polyooxyethylene/polyoxypropylene copolymers; and ethoxylated alkyl phenols.
  • a fluid composition of the present invention includes one or more emulsifiers in an amount of about 0.1 wt % to about 20 wt % of the fluid composition; about 0.5 wt % to about 18 wt % of the fluid composition; about 1 wt % to about 16 wt % of the fluid composition; about 2 wt % to about 14 wt % of the fluid composition; about 2 wt % to about 12 wt % of the fluid composition; about 3 wt % to about 11 wt % of the fluid composition; about 4 wt % to about 10 wt % of the fluid composition; about 0.1 wt % of the fluid composition; about 0.5 wt % of the fluid composition; about 1 wt % of the fluid composition; about 2 wt % of the fluid composition; about 3 wt % of the fluid composition; about 4 wt % of the fluid composition; about 5 wt % of the fluid composition;
  • a metalworking fluid composition described according to the present invention and suitable for use in the machining of iron such as compacted graphite iron consists of:
  • synthetic polyol fatty acid esters such as trimethyolpropane trioleate, pentaerythritol tetradodecanoate, neopentylglycol dioleate, and isopropyl oleate as well as those produced by the initial reaction of the polyol with ethylene oxide and/or propylene oxide followed by subsequent esterification, to yield a polyoxyalkylated polyol ester.
  • a sulfur-containing compound selected from di-branched alkyl polysulfides, sulfurized alpha olefins and complex sulfurized fatty acids and fatty acid esters;
  • amines include ethanolamine, triethanolamine, 2-amino-2-methyl propanol, dicyclohexylamine, and diglycolamine.
  • boric acid amine adduct may be comprised of a mixture of one or more structures which include the amine salts of boric acid, boric acid-alkonaolamine esters including cyclic boroxine esters, as well as polyborate amine salts.
  • Such fluid compositions when blended in an amount of about 2 wt % to about 15 wt % in water, and utilized in the machining of iron such as compacted graphite iron, produce a significant decrease in the rate of tool wear which occurs as well as a noticeable enhancement in the quality of the part machined.
  • a fluid useful for the improved machining of iron such as compacted graphite iron includes:
  • R 1 ⁇ H or —CH 2 CH 2 OH, R 2 ⁇ H, or —CH 2 CH 2 OH, or cyclic C 6 H 11
  • R 3 ⁇ or —CH 2 CH 2 OH, or cyclic C 6 H 11
  • Such fluid compositions when blended in an amount of about 3 wt % to about 15% in water, and utilized in the machining of iron such as compacted graphite iron, produce a noticeable decrease in the rate of tool wear which occurs as well as a noticeable enhancement in the quality of the part machined. Results of machining tests described below show the utility and advancement realized with such compositions in the machining of iron such as compacted graphite iron.
  • fluid compositions of the present invention may be blended with water to prepare a dilution.
  • fluid compositions of the present invention may be blended in water in an amount of about 1 wt % to about 50 wt % of the dilution; about 2 wt % to about 25 wt % of the dilution; about 3 wt % to about 20 wt % of the dilution; about 3 wt % to about 17 wt % of the dilution; about 4 wt % to about 15 wt % of the dilution; about 1 wt % of the dilution; about 2 wt % of the dilution; about 3 wt % of the dilution; about 4 wt % of the dilution; about 5 wt % of the dilution; about 6 wt % of the dilution; about 7 wt % of the dilution;
  • fluid compositions according to embodiments of the present invention during machining iron such as compacted graphite iron results in a reduction in tool wear as compared to conventional fluids of about 5% to about 95%; about 10% to about 90%; about 15% to about 85%; about 20% to about 80%; about 25% to about 75%; about 30% to about 70%; about 35% to about 65%; about 40% to about 60%; about 5%; about 10%; about 15%; about 20%; about 25%; about 30%; about 35%; about 40%; about 45%; about 50%; about 55%; about 60%; about 65%; about 70%; about 75%; about 80%; about 85%; about 90%; or about 95%.
  • Drilling is a process whereby holes are produced in the workpiece metal, and in such, greater amounts of metal are removed, which typically requires greater cutting forces and gives rise to more severe mechanical and thermal conditions in the process.
  • Assessment of fluid performance is made by measurement of the cutting forces and tool wear occurring during the drilling operation.
  • Fluid A useful for the improved machining of compacted graphite iron, was prepared according to embodiments of the present invention having:
  • Fluid A was tested at a concentration of 8%.
  • the machining conditions are as follows:
  • the axial machining forces and torque (tangential forces) measured during drilling provide a useful indication of the friction in the cutting zone and the lubrication provided by the metalworking fluid.
  • the change in the forces measured as drilling continues may provide a useful indirect measure of the change or deterioration in the condition of the tool, typically arising from tool wear and/or metal adhesion on the cutting edge.
  • use of Fluid A enables for the machining of compacted graphite iron at considerably lower cutting forces and change in forces relative to that which occurs when the conventional ferrous machining fluid (Fluid B) is used.
  • Fluid D useful for the improved machining of compacted graphite iron, was prepared according to embodiments of the present invention having:
  • fatty acids comprised of those which include saturated alkyl chains of between 10 to 16 carbons along with longer chain length carboxylic acids comprised of saturated and unsaturated alkyl chains of between 18 to 22 carbon atoms in length.
  • Fluid D was tested in drilling tests along with two currently used compacted graphite iron machining fluids which are based on conventional ferrous machining fluid compositions. These two fluids designated Fluid C and Fluid E, both represent the state of the art technology available for compacted graphite iron machining prior to that of the current fluid compositions described in this invention. Also included in this testing and comparison is Fluid A.
  • FIGS. 3 and 4 The results of tool wear measured during compacted graphite iron drilling using the four fluids is shown below in FIGS. 3 and 4 .
  • the results demonstrate that Fluid A and Fluid D clearly yield a significant reduction in tool wear, and thus extend the useful duration of the tooling.
  • the results show that Fluid A and Fluid D result in a range of tool wear reduction between about 22% to about 46% representing significant benefit with regard to the machining operations and the cost associated with the process.
  • Fluid F useful for the improved machining of compacted graphite iron, was prepared according to embodiments of the present invention having:
  • Such fluid compositions when blended in an amount of about 4 wt % to about 15 wt % in water, and utilized in the machining of iron such as compacted graphite iron, produce a noticeable decrease in the rate of tool wear which occurs as well as a noticeable enhancement in the quality of the part machined.
  • Fluid F was tested in the drilling and reaming of Grade 450 CGI at a concentration of 8%. This fluid composition was tested along with and compared to the performance of a conventional machining fluid utilized for cast iron machining (including CGI), Fluid G. Fluid G is similar to Fluid F in composition but does not contain the sulfur based additive.
  • the torque (tangential forces) measured during drilling provides a useful indication of the friction in the cutting zone and the lubrication provided by the metalworking fluid.
  • the change in the torque measured as drilling continues reflects the changes (wear) occurring on the tools cutting edge as drilling continues.
  • FIG. 5 the lower machinability and greater challenge inherent in the machining of compacted graphite iron relative to a standard Class 40 gray cast iron is clearly seen.
  • Fluid F a fluid according to embodiments of the present invention
  • FIG. 6 shows the tool wear obtained on the drills used. As seen and consistent with the cutting forces measured, while significantly higher wear occurs in compacted graphite iron machining relative to gray cast iron machining, the use of Fluid F enables for the effective reduction of wear on the tool cutting edge.
  • Fluid B a standard conventional ferrous machining fluid along with a fluid described according to embodiments of the current invention were assessed in a turning operation utilized to simulate the continuous cutting conditions which occur during engine cylinder boring.
  • Fluid A useful for the improved machining of compacted graphite iron, was prepared according to embodiments of the present invention having:
  • Fluid A was tested at a concentration of 9%.
  • the machining conditions are as follows:

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BR112014013879A2 (pt) 2017-06-13
JP2015503012A (ja) 2015-01-29
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MX2014006721A (es) 2014-10-13
EP2788461A4 (en) 2015-08-19

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